{"id":2107,"date":"2019-12-17T09:32:19","date_gmt":"2019-12-17T09:32:19","guid":{"rendered":"https:\/\/verdes.devgrafix.com\/?p=1291"},"modified":"2022-07-13T09:07:11","modified_gmt":"2022-07-13T09:07:11","slug":"the-ceramic-split-tile-production-technique-with-verdes-extruders","status":"publish","type":"post","link":"https:\/\/verdes.com\/en\/verdesmachines\/the-ceramic-split-tile-production-technique-with-verdes-extruders\/","title":{"rendered":"The ceramic split-tile production technique with Verd\u00e9s extruders"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">As you may know, we find the\norigin of the very first ceramic tiles and mosaics in the Ancient History (in the\nBabylonian and Roman Empires). Then in the middle age, after centuries of austerity\nand decline, the use of ceramic tiles as ornamental element in monuments and\npublic buildings, became popular again thanks to the influence of the Muslims\nwho introduced their techniques and geometrical designs in Europe through Spain\nand the old Al-Andalus. <\/p>\n\n\n\n<figure class=\"wp-block-gallery columns-3 is-cropped wp-block-gallery-1 is-layout-flex wp-block-gallery-is-layout-flex\"><ul class=\"blocks-gallery-grid\"><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/Berlin_-_Pergamon_Museum_-_Persian_warriors_-_20150523_6849-1-600x600.jpg\" alt=\"\" data-id=\"1296\" data-link=\"https:\/\/verdes.com\/?attachment_id=1296\" class=\"wp-image-1296\"\/><figcaption class=\"blocks-gallery-item__caption\">Old Babylonian tiles<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/details-roman-mosaic-floor-shallow-depth-field-roman-mosaic-floor-shallow-depth-field-136869152-600x408.jpg\" alt=\"\" data-id=\"1297\" data-link=\"https:\/\/verdes.com\/?attachment_id=1297\" class=\"wp-image-1297\"\/><figcaption class=\"blocks-gallery-item__caption\">Old Roman mosaic<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/03_azulejos-mudejares-azulejos-andaluces-dosde-publishing-600x600.jpg\" alt=\"\" data-id=\"1299\" data-full-url=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/03_azulejos-mudejares-azulejos-andaluces-dosde-publishing.jpg\" data-link=\"https:\/\/verdes.com\/?attachment_id=1299\" class=\"wp-image-1299\"\/><figcaption class=\"blocks-gallery-item__caption\">Old andalusi tiles<\/figcaption><\/figure><\/li><\/ul><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">So, as we see ceramic tiles in Spain have a very long tradition and popularity. And over the centuries artisans and producers have improved and evolved their production techniques up to the industrial and technological ceramic tile production process of the modern times.<\/p>\n\n\n\n<div class=\"wp-block-image\"><figure class=\"alignright size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/1_Extrusora-Desver-1927.jpg\" alt=\"The very first Verd\u00e9s extruder (1924)\" class=\"wp-image-1302\" width=\"420\" height=\"430\"\/><\/figure><\/div>\n\n\n\n<p class=\"wp-block-paragraph\">  Thanks to this long tradition and deep roots of the ceramic products in  the Spanish and Mediterranean cultures, nowadays Spain is the country  that leads the production of the industry, both in terms of quantity and  quality of the ceramic products, and also the export figures, being the  second country in number of ceramic product exportations, just  surpassed by China.  <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Hence at Verd\u00e9s, with more\nthan 111 years of history, and hundreds of active Verd\u00e9s machines spread over\nSpain and thousands of them currently working in more than 60 countries, we\nfeel very proud of being part of the ceramic tile modern history by helping our\nClients with our clay preparation and shaping machines.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Nowadays, among the heavy clay sector, a steady growing demand is observed only for products with outstanding technical and aesthetic characteristics such as top-quality ceramic tiles and steps, ventilated facades, facing bricks and roof tiles. Thus, we would like to illustrate how ceramic tiles and steps are made with Verd\u00e9s machines following the split-tile system.<\/p>\n\n\n\n<figure class=\"wp-block-gallery columns-4 is-cropped wp-block-gallery-2 is-layout-flex wp-block-gallery-is-layout-flex\"><ul class=\"blocks-gallery-grid\"><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/ventilated-600x600.jpg\" alt=\"\" data-id=\"1312\" data-link=\"https:\/\/verdes.com\/?attachment_id=1312\" class=\"wp-image-1312\"\/><figcaption class=\"blocks-gallery-item__caption\">ventilated facades<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/klinker-grestejo-d1-1-600x600.jpg\" alt=\"\" data-id=\"1313\" data-full-url=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/klinker-grestejo-d1-1.jpg\" data-link=\"https:\/\/verdes.com\/?attachment_id=1313\" class=\"wp-image-1313\"\/><figcaption class=\"blocks-gallery-item__caption\">gres klinker steps<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/revestimentos1-1ace2fb7-1-600x381.jpeg\" alt=\"\" data-id=\"1314\" data-full-url=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/revestimentos1-1ace2fb7-1.jpeg\" data-link=\"https:\/\/verdes.com\/?attachment_id=1314\" class=\"wp-image-1314\"\/><figcaption class=\"blocks-gallery-item__caption\">facing bricks<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/rojo-cazorla_jpg-1-600x535.jpg\" alt=\"\" data-id=\"1315\" data-full-url=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/rojo-cazorla_jpg-1.jpg\" data-link=\"https:\/\/verdes.com\/?attachment_id=1315\" class=\"wp-image-1315\"\/><figcaption class=\"blocks-gallery-item__caption\">roof tiles<\/figcaption><\/figure><\/li><\/ul><\/figure>\n\n\n\n<div class=\"wp-block-image\"><figure class=\"alignright size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/chamotte.jpg\" alt=\"LTR - Precrushed chamotte with Verd\u00e9s primary crusher \/ fine crushed chamotte with Verd\u00e9s hammer mills\" class=\"wp-image-1316\" width=\"457\" height=\"356\"\/><\/figure><\/div>\n\n\n\n<p class=\"wp-block-paragraph\">Clinker steps and floor tiles are exclusively made from varieties of high-melting clays. The obligatory composition of the recipe for this clinker is \u201cchamotte\u201d (aka grog, firesand) &#8211; this is essentially the same clinker that has already been fired in a kiln, but after that it is crushed by hammer mill and added to the clay mix in preparation area from a 5% to 15%. Chamotte is necessary for the &#8220;lean of the mass&#8221; &#8211; i.e. reducing plasticity, it improves drying characteristics, reduces fire shrinkage, facilitates the firing mode (heating mode and cooling mode), does not change the chemical composition of the mixture (raw materials). In addition, the use of chamotte in the charge is important from the point of view of environmental protection and the creation of non-waste production technology. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Clinker is normally produced by the method of vertical extrusion, being the <a href=\"https:\/\/verdes.com\/en\/magna-extruders.html\">Verd\u00e9s Magna<\/a> and <a href=\"https:\/\/verdes.com\/en\/magnabloc-extruders.html\">Magnabloc<\/a> extruders, the ideal machine for this process. At the modern plants, right after the cutter, raw material is moved by fully automated setting systems without touching of front surfaces. After the material enters the drying chambers, where the raw material units are dried up to 40 hours at a temperature of 90 to 98 Celsius degrees. After preliminary drying, the raw materials are supplied on the conveyor belt for glazing and painting (if necessary). Further, the workpieces by mechanisms are placed in a special way on the carriage in 2-3-4 rows in height and undergo long-term firing on the carriage in a tunnel kiln 100 or more meters long at a temperature of 1100 to 1300 Celsius degrees for 70-80 hours (3 days). <\/p>\n\n\n\n<figure class=\"wp-block-gallery columns-3 wp-block-gallery-3 is-layout-flex wp-block-gallery-is-layout-flex\"><ul class=\"blocks-gallery-grid\"><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/vlcsnap-2019-12-17-08h36m00s31822222-600x600.jpg\" alt=\"\" data-id=\"1328\" data-full-url=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/vlcsnap-2019-12-17-08h36m00s31822222.jpg\" data-link=\"https:\/\/verdes.com\/?attachment_id=1328\" class=\"wp-image-1328\"\/><figcaption class=\"blocks-gallery-item__caption\">Verd\u00e9s split tile extruder<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/vlcsnap-2019-12-17-08h37m49s847-1-600x600.jpg\" alt=\"\" data-id=\"1326\" data-link=\"https:\/\/verdes.com\/?attachment_id=1326\" class=\"wp-image-1326\"\/><figcaption class=\"blocks-gallery-item__caption\">split tile<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/20180918_155707-600x600.jpg\" alt=\"\" data-id=\"1321\" data-link=\"https:\/\/verdes.com\/?attachment_id=1321\" class=\"wp-image-1321\"\/><figcaption class=\"blocks-gallery-item__caption\">split tile<\/figcaption><\/figure><\/li><\/ul><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">After the steps and tiles have\nbeen fired in a tunnel kiln &#8211; they are &#8220;separated&#8221; from each other by\nspecial equipment. That\u2019s why this technology is called split-tile. This is\nfollowed by packaging in boxes and on pallets. After which the material is sent\nto customers.<\/p>\n\n\n\n<div class=\"wp-block-image\"><figure class=\"alignright size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/Verd\u00e9s-Primary-Crusher.-scaled.jpg\" alt=\"Verd\u00e9s Primary Crusher\" class=\"wp-image-1329\" width=\"372\" height=\"277\"\/><\/figure><\/div>\n\n\n\n<p class=\"wp-block-paragraph\">For all this, clinker\nproduction technology is based on the proper preparation of raw materials. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">At this point, the producer must homogenize the clay and eliminate the heterogeneity that is characteristic of it in the quarry, ensuring the supply of material with constant characteristics to the plant. In addition to the natural physical impact of the environment, to destroy large lumps of freshly extracted clay, it makes sense to use a <a href=\"https:\/\/verdes.com\/en\/primary-crushers.html\">Verd\u00e9s Primary Crusher <\/a>already at this stage.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">However, the key aspect of the manufacturing process is to obtain a FINE grinding of raw materials. So fine milling can be achieved both by dry and semi-wet methods with <a href=\"https:\/\/verdes.com\/en\/machines.html\">Verd\u00e9s machines<\/a>. Each of these methods has several features:<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">&#8211; Dry method of preparation of raw materials: produced by <a href=\"https:\/\/verdes.com\/en\/hammer-mills.html\">Verd\u00e9s Hammer Mills<\/a> (grinding with a thickness of up to 0.2 &#8230; 0.7 mm), or <a href=\"https:\/\/verdes.com\/en\/pendulum-mills.html\">Verd\u00e9s Pendulum Mills<\/a> (grinding with a thickness of less than 200 microns).<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">&#8211; Semi-wet method of preparation of raw materials: involves the use of a cascade of <a href=\"https:\/\/verdes.com\/en\/optima-roller-mills.html\">Verd\u00e9s OPTIMA Roller Mills<\/a>, including at the end a Verd\u00e9s OPTIMA fine roller mill for grinding at real working gap of 0.6 &#8230; 0.8 mm.<\/p>\n\n\n\n<figure class=\"wp-block-gallery columns-3 is-cropped wp-block-gallery-4 is-layout-flex wp-block-gallery-is-layout-flex\"><ul class=\"blocks-gallery-grid\"><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/hammer-mill-4-2-600x430.jpg\" alt=\"\" data-id=\"1344\" data-full-url=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/hammer-mill-4-2.jpg\" data-link=\"https:\/\/verdes.com\/?attachment_id=1344\" class=\"wp-image-1344\"\/><figcaption class=\"blocks-gallery-item__caption\">Verd\u00e9s Hammer mills<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/Pendular2-1-600x600.jpg\" alt=\"\" data-id=\"1338\" data-link=\"https:\/\/verdes.com\/?attachment_id=1338\" class=\"wp-image-1338\"\/><figcaption class=\"blocks-gallery-item__caption\">Verd\u00e9s Pendulum Mill<\/figcaption><\/figure><\/li><li class=\"blocks-gallery-item\"><figure><img decoding=\"async\" src=\"https:\/\/verdes.com\/wp-content\/uploads\/2019\/12\/Optima-Roller-Mill-Astana-600x600.jpg\" alt=\"\" data-id=\"1340\" data-link=\"https:\/\/verdes.com\/?attachment_id=1340\" class=\"wp-image-1340\"\/><figcaption class=\"blocks-gallery-item__caption\">Verd\u00e9s Optima Roller Mill<\/figcaption><\/figure><\/li><\/ul><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">At Verd\u00e9s we let our Customers to perform previous grinding tests with their clays in our modern<a href=\"https:\/\/verdes.com\/en\/lab.php\"> laboratory facilities<\/a>. Equipped with process <a href=\"https:\/\/verdes.com\/en\/laboratory-machines.html\">machinery<\/a>, including a hammer mill, roller mill, disintegrator, mixer and extruder and other measuring devices. This is a service that Verd\u00e9s provides to its customers in order to select the most suitable grinding and extrusion processes, whilst ensuring performance and the quality of the final product that the client will produce.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>As you may know, we find the origin of the&#8230;<\/p>\n","protected":false},"author":1,"featured_media":2164,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[24,23],"tags":[],"class_list":["post-2107","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-technical","category-verdesmachines"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.9 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>The ceramic split-tile production technique with Verd\u00e9s extruders - 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